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Discussion Starter #1
I work on Duramaxs and rebuild Allisons on the side and also brought athis was a real fun week, Not.

A guy brought me an 03 with a couple bad injectors SHOCKER... He also brought an engine from an 05 as he don't want to do the injectors again. I swapped everything over for the new engine, waited a few days for the new ECM and intake duct. It fired right up and then started knocking and has a ton of blowby...SWEET!!!! I'm guessing it has a busted piston, I'll be pulling it this week once the warranty crap is strait. Fun!
 

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I Just Break Stuff
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Yea that sounds like loads of fun. Guess that first swap was just for practice huh. Yup........... That pretty much SUCKS.
 

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Discussion Starter #3
Yeah, I was all stoked, this was the quickest I ever did one of these.... 9 hours with the whole wire harness change. Talk about a buzz kill.
 

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PSN Pretender
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LOL.....I did one a while back.

Dealer put all new injectors in it because of an engine noise. Well customer came in to pick it up and it wouldn't start. So they drag it back in the shop and a little while later come out and say the engine is bad. Ohh and your warranty wont cover any of it. This thing was bone stock!

Eventually it got towed to our shop to diagnose the problem. Found that 2 exhaust valves dropped in the engine and destroyed the engine. Customer finds a used engine to replace it with and asked if we could swap all of his "new" injectors into his "new" engine. Of course the injector with the dropped valves was junk, but came to find out none of the injectors were even replaced. Took me almost half a day just to get the injectors out of the damn thing, and they were totally coated in crap. Luckley the "new" engine ran OK with minimal blowby.........fffhheeewww.

I would hate to be that guy.
 

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I Just Break Stuff
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Awe man. That gives me a funny little knot in my stomach just thinking about that. I've been pretty close to that before. It ain't nothin nice that's for sure.
 

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Sponge
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Hey, what's the deal with these trucks? I haven't had the chance to look at this truck, but a friend of a friend has a duramax that had an injector issue then a water pump issue. The shop did the first one and charged a heap of cash because "it's buried. gotta take a bunch of stuff off. blah blah blah" Then the quote for the water pump was something like $800 or something for the same reason. This wasn't the stealership, just some local place that's supposed to specialize in duramax. The dude did the water pump himself, but seemed to verify the fact that it was a huge hassle.
Are these trucks really that much more of a pain to work on than Int'l/Cummins? Or is this shop just making some money and the guy my buddy knows isn't much of a mechanic?
 

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Discussion Starter #7
I let a dealer change my injectors under warranty, only because of the cost of the parts. I should have just done it myself. They gave my truck back to me leaking fuel and coolant, broke the wires off my WIF sensor and a hand full of other problems. Won't make that mistake again...
 

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Discussion Starter #8
They're not bad to work on, for a mechanic. I've only ever met ONE mechanic that worked at a dealer my whole life. Dealers hire "techs" and charge mechanic rates. A lot of shops out there are in the business of making money, not doing good work and getting paid for it.
 

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Hey, what's the deal with these trucks? I haven't had the chance to look at this truck, but a friend of a friend has a duramax that had an injector issue then a water pump issue. The shop did the first one and charged a heap of cash because "it's buried. gotta take a bunch of stuff off. blah blah blah" Then the quote for the water pump was something like $800 or something for the same reason. This wasn't the stealership, just some local place that's supposed to specialize in duramax. The dude did the water pump himself, but seemed to verify the fact that it was a huge hassle.
Are these trucks really that much more of a pain to work on than Int'l/Cummins? Or is this shop just making some money and the guy my buddy knows isn't much of a mechanic?

The water pump is a pain in the ass because the starter has to come off to put a flywheel holder tool in there. Turns out that the Duramax has ONE water pump bolt that is half covered by the front harmonic balancer.....which has a 36mm 12 pt. bolt holding it on. It's always fun using a 3/4" breaker bar with a 4 foot cheater on it just to break that bolt loose. At least it's not a pressed on balancer. Add on top of that the retarded steel bypass line with a small hose connected to it that's a giant abortion of a mess just to weasel in and out of the space between the bottom of the thermostat housing and the top of the water pump. Oh, and the water pumps don't come complete anymore. You used to get the housing with the pump....now you get to transfer the pump to the old cavitated housing. Nope, never done one.



The injectors are a pain because yes, the rocker covers (upper and lower boxes) have to come off. They are held on by a boatload of 5mm allen bolts. The uppers have to be pried off since they're glued on with sealant.
The passenger side requires removal of the FICM and fuel filter assembly (after you fish the intercooler tube out), while the driver's side is buried under the upper radiator hose pipe and engine harness connector bracketry. These few little items add up time wise. Don't forget the BURIED injector lines themselves. A crows foot socket comes in really handy and if you're lucky you won't have to clean the corrosion off of the taper on end of the lines inside the fittings (sand-blaster time).

Once the rocker covers are removed (as well as the injector pass-through harness that have two nuts/wires per injector and two bolts holding each pair of injector leads to the rocker shaft bosses), the return lines and sealing washers get to be removed. Again, 5mm allens with a 12mm banjo bolt into the head at the end. Now comes the fun part....getting the injectors out without bringing the injector cups with them. Once the 8mm allen hold down bolts are out, you can pull out the injectors. I use an old injector line and a small 6" pry bar....twist and pull (sounds like a porno).

Going back together....there's a lot of torquing going on.

Basically, injectors can be done in about 6 hours........and don't plan on warranty replacing them if they don't have high return rates (and in that case have 15 pages worth of diagnostic sheets and scan tool screenshots accompanying the cores).
 

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Damn and we complain about working on the 6.0s :ford:
 

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Sponge
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The water pump is a pain in the ass because the starter has to come off
Dude. That is awesome! The first line is all I needed.

But thanks for the rest. I was an interesting read. And it honestly doesn't sound that bad. Just a few issues that sound like they could cause headaches, but not if you do it all the time.
 

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Dieselis' Maximus
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Hey, what's the deal with these trucks? I haven't had the chance to look at this truck, but a friend of a friend has a duramax that had an injector issue then a water pump issue. The shop did the first one and charged a heap of cash because "it's buried. gotta take a bunch of stuff off. blah blah blah" Then the quote for the water pump was something like $800 or something for the same reason. This wasn't the stealership, just some local place that's supposed to specialize in duramax. The dude did the water pump himself, but seemed to verify the fact that it was a huge hassle.
Are these trucks really that much more of a pain to work on than Int'l/Cummins? Or is this shop just making some money and the guy my buddy knows isn't much of a mechanic?

I helped my buddy with his 06 duramax doing an S-475 turbo. he had a custom intake that he had fabbed up, custom pedestal for the turbo. It was a pretty darn nice set up. OMG what a PIA to get to just the stock turbo to take it off... then we had to put a 4"down pipe on it....Lets just say I will have repressed memories about that. I only helped him when we started taking the factory crap off. That was fairly smooth 4 or so hours... I take that back Getting the up-pipes off was a PIA he said he had to unbolt the tranny and jack it up a few inches. He spent a few hours over a couple of days getting it as far as he could.

I was able to help him again this last Friday we got out of work early and headed up there. We started at about 4pm and finished at almost 5AM the next morning. :poke: :mad: :poke:

His truck is a Friggin BEAST though!
 

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OMG what a PIA to get to just the stock turbo to take it off... then we had to put a 4"down pipe on it....Lets just say I will have repressed memories about that. I only helped him when we started taking the factory crap off. That was fairly smooth 4 or so hours... I take that back Getting the up-pipes off was a PIA he said he had to unbolt the tranny and jack it up a few inches. He spent a few hours over a couple of days getting it as far as he could.

Yeah, the turbochargers are a nightmare. After the first one I fought for 8 hours I finally just started automatically dropping the transmission right off the bat. Turns the turbo into a 4 hour job at the most because you can then use air tools for the turbine inlet pipes (up-pipes).
 

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Discussion Starter #15
There still better than any PSD to date, but the6.7 might change that.
 

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All done now
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There still better than any PSD to date, but the6.7 might change that.
Huh?

Convince the D-Max I spanked on the way to work this morning. Nothing but a chip, intake, and open exhaust. And I am running single shots tunes on split shot injectors.
 

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Discussion Starter #17
Fired it up to move it and pull the engine tonight, and it locked up..WTF
 

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Serves you right D-bag
 
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